ML20044D459
| ML20044D459 | |
| Person / Time | |
|---|---|
| Site: | 05200004 |
| Issue date: | 03/23/1992 |
| From: | Frederick D, Kafadar C OEA, INC. |
| To: | |
| Shared Package | |
| ML20044D433 | List: |
| References | |
| 76581, NUDOCS 9305190169 | |
| Download: ML20044D459 (17) | |
Text
.
TECHNICAL PROPOSAL FOR SQUIB VALVES Pyrenetics PN 1132 MOD GE Specification: 23ATBD GE Nuclear RFQ EH206 Pyronetics Proposal 76581 Prepared By:
OEA Pyronetics Division Denver, Colorado CAGE Code:
19689 Prepared For:
GE Nuclear San Jose, California Issue Date:
23 March 1992
\\
/
9305190169 930514 PDR ADOCK 05200004 A
76581 TECHNICAL PROPOSAL FOR l
SQUIB VALVES Pyronetics Proposal 76581
SUMMARY
l l
Pyronetics is pleased to submit this proposal in response to the GE RFQ EH206.
We propose to provide the required valves (either 4" or 6") completely in accordance with the preliminary GE Specification 23ATBD. Our proposed valves, PN 76562-1 (6") and 76562-2 (4") are modified versions of our PN 1132 valve which was designed and developed for GE Nuclear.
Pyronetics has the necessary technical and manufacturing expertise in design, development, and testing to ensure that the Valve Program will be completed on schedule.
If additional details are required for the evaluation of this proposal, they can be promptly supplied..
We will be glad to undertake this program as proposed or to consider any modification which may be required to our design approach or to GE's specification.
The Pyronetics' personnel who contributed to this proposal include:
C.
B. Kafadar, D.
C.
Frederick, J. L. Hubbard and S. P.
l Tripathi.
j i
Respectfully Submitted, OEA Pyronetics Division
.k D.
C.
Frederick General Manger APPROVED:
}
db C.
Kafada President l
ii
76581 TABLE OF CONTENTS SECTION DESCRIPTION PAGE NO
SUMMARY
11 TABLE OF CONTENTS iii
1.0 INTRODUCTION
1 1.1 Backaround and ExDerience 1
2.0 TECHNICAL PRESENTATION 3
2.1 Desian Description.
3 2.2 Performance Characteristics and Analysis.
4 2.3 Test Procram.
7 2.4 Weicht 8
2.5 Life.
8 2.6 Maintainabilitv/ Human Encineerinc 9
2.7 Safety 9
2.8 Related ExDerience 9
2.9 Reliability 9
2.10 Potential Problem Areas 9
2.11 Comments. Clarifications, and Exceptions.
10 TABLE I SQUIB VALVES 11 TABLE II Comparison of FIAT & Previous Pyronetics Valve FN 1132 18 l
TABLE III Review of Specification Requirements 19 I
TABLE IV Schedule 29 FIGURE 1 - Proposed Valves -1,
-2 30 FIGURE 2 - PN 1132 32 FIGURE 3 - PN 1366-2 34 FIGURE 4 - PN 1166 36 FIGURE 5 - PN 3579 37 APPENDIX A Document 7-3579 A-0 APPENDIX B Document 7-1132 B-0 APPENDIX C Document 17-1132 C-0 l
l I
iii
76581 TECHNICAL PROPOSAL i
i 4
FOR i
SQUIB VALVES 4
l Pyronetics Proposal 76581 i
i a
1.0 INTRODUCTION
j This document outlines Pyronatics' proposed design and delivery of the squib valves completely in accordance with the preliminary GE Specification 23ATBD.
l l
The proposed valves, PN 76562-1 and ' -2 (See Figure 1) are manufactured primarily from 304L stainless steel.
Two initiators in conjunction with a single booster charge provides the energy necessary to actuate the valves.
The proposed valves have the simplicity, compactness, and low pressure loss exhibited by other valves designed and qualified by Pyronetics.
i 1.1 Backaround and Experience In preparing this proposal, Pyronetics has drawn upon the l
continuous experience of its personnel since 1969, in the design and development of high reliability devices for commercial use and' i
military missile and spacecraft-applications.
~ testing, and background is especially suited for the development,. Pyronatics' manufacture of either or both of the two configurations of squib valves.
The experience. gained by Pyronatics on the previous Depressurization Valve for GE Nuclear (a 7 inch flow path) may be applied directly to the two smaller valve configurations required I
by GE Nuclear.
The entire actuator subassembly (ballistic part of the valve) of the existing PN 1132, (See Figure 2),.Depressurization Valve, may be used with only one minor change.
This change is required to.
incorporate welded straps which will serve as an anti-rotation device during environmental testing exposure.
The same initiator and booster propellant material previously accepted by GE for.the Depressurization Valve program can be used for GE's application.
The flow passage end of the, valve will be revised to incorporate a dual nipple design which allows for the system outlet back pressure 4
requirenant.
Our nipple design is based upon our two (2) inch normally closed valve used by Martin on the Space Shuttle External Tank.
The sizing up of this PN 1366-2 valve (See Figure 3), will s
be performed in a similar manner to our procedure used on the PN 1132. valve where we sized up a two (2) inch flow path valve (PN 1166, see Figure 4) which was designed for the General Dynamics Shuttle Centaur Program.
1
.. - ~.
1 i
l
[
76581 i
l t
Table I gives a partial listing of squib valves. The proposed squib valves are similar to numerous valves previously built and qualified by Pyronatics as shown in Table I.
These valves are in nearly continuous production.
We are therefore not faced with i
phase-in and phase-out problems, our personnel in every department have the expertise and experience necessary to support the I
development and production programs of either-or both of the two i
f I
i l
t i
f l
i i
b 1
I i
l 2
i i
76581 2.0 TECHNICAL PRESENTATION GE's Request for Quotation, EH206, gives the requirements for l
the performance, design, development, and test of the squib valves.
l Pyronetics accepts every paragraph of the GE specification 23ATBD l
except as noted herein. A cross-reference table correlating valve l
requirements of the GE specification with those of this proposal, l
is given in Table III herein.
l l
2.1 Desian Descriotion The valves perform the following two basic operations in any attitude:
a)
When closed, the valve prevents any leakage through the valve under all environmental conditions of storage and handling.
b)
When actuated, the valve provides a straight through flow path without restriction.
Our proposed valves are shown on drawing 76562.
See Table II for a comparison of our proposed valves to the FIAT requirements.
The differences between the proposed valves and the 1132 GE Nuclear valve are as follows:
a)
The proposed valves are smaller versions of our 1132 valve with respect to the flow path and body size.
b)
Two nipples instead of one.
Key features and benefits of the proposed design are as follows:
a)
Commonality of design features to a long list of highly successful valves.
b)
The materials and processed employed are common to numerous Pyronetics valves and devices.
c)
Integrally machined nipples (or diaphragus) on the inlet and outlet provide maximum assurance for zero leakage (complete with 100% proof testing and 100% inspection for high reliability).
d)
Straight through passage between inlet and outlet after actuation.
e)
Positive retention of the nipple ends and ram after actuation to preclude flow blockage at the outlet end of the valve.
i l
3
76581 f)
Use of bolts for the installation of the inlet and outlet nipples to the housing to provide both rigidity of construction ' and to provide a means of refurbishment after valve actuation.
g) 0-ring seals not requiring age life controls (all metal).
h)
Eye bolts provide for ease of assembly / disassembly.
1)
A lug on the housing allows for lifting during transportation.
j)
An electrical switch is provided to monitor valve position in the control room.
GE shall. provide the control room monitoring equipment.
k)
Substantial amount of testing already -completed by Pyronetics and GE Nuclear has already verified the valves and propellant materials ability to meet virtually all of the GE requirements for the squib valves.
1)
Development costs will be dramatically reduced based upon the prior development testing of the PN 1132.
m)
The valves are refurbishable.
2.2 Performance' Characteristics and Analysis 2.2.1 Valve Operation The proposed valves are shown ' in drawing _76562 (see Figure 1).
These valves use design features which have already been used in our other qualified valves.
Therefore, Pyronetics will provide a very reliable design for GE's application.
Upon actuation of either or both initiators, a
pyrotechnic booster charge is ignited and hot gases are produced.
When these gases reach a designed pressure, a tension bolt holding a piston breaks allowing the piston to travel downward until it impacts the ran and nipple shear caps.
Once the piston impacts the ran and nipple shear caps, the nipples are sheared.
The ram and shear caps are then driven forward and are locked in place at the end of stroke by an interference fit with the nipple retainer.
This lock insures that the nipples can not block the flow stream and provides a simplo means of refurbishment by simply unthreading the plug.
The lockinq feature and basic valve flow path design are based upon our 1366-2 valve (see Figure 3) which provides a faster response time during actuation than does the PN 1132_ (see Figure 2)
" flapper" design.
A switch located. on the. bottom of ' the valve provides a method of indication to the control room of an actuated valve.
This switch is a modified version-(longer) of our PN 1132 switch.
The shear nipple sections are designed to produce clean shear planes.
This feature is not degraded by long term environments and is fully qualified in numerous Air Force, Navy, Army, and space applications.
4
I 1
76581
\\
l' The piston is allowed to back up after shearing the nipples.
This design concept for the piston (not locked in place after actuation) is used by Pyronetics for all our squib valves used with a high pressure compressed gas system (e.g. our PN 3339-4 for TRW on the Tomahawk Program and in our previous PN 1132 for GE
[
Nuclear).
Standard metal seals are installed on the piston to reduce the potential of ballistic products from entering the flow l
path.
The proposed valves are completely refurbishable.
The l
refurbishment can be performed within the GE specified time frame.
A refurb procedure will be provided after contract award.
2.2.2 Valve Materials and Processes The housing, nipples, adapter flanges, actuator housing, indicator switch body, indicator plunger, head cap,
- coupling, collar and adapter are machined from 304L CRES.
This material is entirely suited to the proposed design.
This material as well as all other materials outlined for usage and described herein, for our proposed valves, are identical materials as those previously used on the GE Nuclear Depressurization Valve.
The piston, ram, and tension bolt will be made from 17-4PH heat treated to H1075.
This material was chosen because of the strength requirements necessary, for these parts, during valve function.
The inlet and outlet studs will be made from ASME SA 193B7 1Cro.2Mo.
The inlet and outlet nuts vill made from ASME SA 194 Grade 7 1CrO.2Mo.
Our proposed valves are completely interchangeable and will have the same inlet and outlet nipple design which will
" Murphy Proof" the installation at the system level.
2.2.3 Initiator / Booster Assembly 2.2.3.1 Summary Our proposed initiator and booster will be identical to that used in the PN 1132 GE Nuclear Valve.
All components of the initiator and booster will be assembled and tested at OEA.
OEA demonstrated initiator / cartridge experience includes over 6,900,000 units delivered.
Since OEA and Pyronetics are located in the same facility, this leads to easy coordination of the initiator and booster activities to insure that the GE schedule requirements for the valve, initiator and booster are met.
The initiator is based on technology OEA has amply clemonstrated for qualified initiator / cartridges used on the F-4,
- 57, WX, NSI-2, Firebee II, Mercedes, GM Air Bag Program etc. and has been proven by testing in nuclear environments similar to those applicable to the GE program requirements.
5
76581 our proposed booster assembly will contain the same propellant as our booster assembly used by GE Nuclear on the 7"
normally closed Depressurization valve.
The booster assembly temperatures are maintained at levels below the maximum permitted, by GE, by the cooling fins which are part of the Actuator Subassembly.
In the areas of design, manufacture, inspection and quality assurance of propellant and explosive actuated devices, OEA's capabilities have been recognized and OEA's facilities approved, by NASA, Army, Navy, Air Force, and the major aerospace companies.
Therefore, we are confident that OEA's team of specialists can supply initiators and boosters meeting the GE specification in a minimum amount of time.
2.2.3.2 Desian Recuirements The major design requirements for the existing initiator will be identical to those used in all PN 1132 valves (e.g.
electrical,
- leakage, output,etc.)
and will meet all the GE specified requirements.
2.2.3.3 Desian Description
\\
The proposed initiator is shown in OEA drawing 3579 (See Figure 5).
The initiator will be identical to that used previously I
for GE Nuclear for the.Depressurization Valve.
2.2.3.4 Initiator Body Subassembly our proposed initiator body has the following noteworthy design features:
a)
Integral charge holder (ceramic and epoxy not required) b)
Hermetic seal The initiator hermatic sealing operation is performed by the Glass Seal Division of OEA.
The sealing processes used by OEA will meet all the temperature and environmental extremes specified in the GE Specification.
6
76581 2.2.3.5 Pressure Droo The proposed valves will allow for the flow of 650 gpm for the 4 inch valve and 978 gpm for the 6 inch valve since straight through flow passages are provided in the valves after actuation.
The Cv shall be determined based on ambient water testing or equivalent and corrected to 135'F requirements using standard engineering equations as part of a development program.
However, flow testing is considered an engineering development test; therefore, it is not required to be quoted as part of our proposal.
L 2.2.3.6 Stress Analysis Our preliminary stress analysis has been completed.
The proposed valve will meet all the required structural and environmental requirements.
2.3 Test Procram Pyronetics proposed test program is modeled around that acceptable to GE on the 7"
Depressurization Valve.
Therefore, production acceptance tests and development tests will be performed as specified below.
The qualification tests in accordance with Appendix 10 of 23TBD shall be performed, if necessary, by GE.
2.3.1 Individual Production Tests A)
Initiator /Eooster Assembly The testing proposed for the initiator and booster would be identical to that detailed in our 7-3579 Acceptance Test Procedure (See Appendix A).
B)
Souib Valve The testing proposed for the valve will be the same as those tests detailed in para. 3.0 of Document 7-1132 (See Appendix B).
The testing will be modified to agree with those changes necessary as a result of new specification requirements.
2.3.2 Encineerina Develooment Tests (Ref. Appendix 10 of 23ATBD)
A)
Pyronetics will perform the following tests as specified:
1)
Two Functional Tests:
One with a nominal booster and one with a downloaded booster (80%).
The testing will be performed in a manner similar to that shown in Para. 4.0 of Document 7-1132 (See Appendix B), except the unit will be fired twice (total) and the testing will be modified to incorporate the new valve requirements.
7
l o
75581 i
I B)
A heat transfer test will be performed, to determine the temperature at the booster / initiator in a manner similar to that i
which we used on the Depressurizatrion Valve (See Para. 3.1 of Document 17-1132 (See Appendix C).
i l
C)
Eighty (80) closed bomb tests on the initiators and
{
boosters were performed during the Depressurization Valve Program.
It shall be GE's responsibility to perform. irridiation, thermal aging and LOCA tests and specify the number of tests units if l
testing is required.
A cost impact to GE would apply.
Pyronatics l
recommends that GE delete these tests for the following reasons:
3 l
1 1)
We will be using the same propellants for the initiator and booster as' was used on the Depressurization Valve.
Therfore, GE should review l
1 the past program testing requirements, and many, if l
not all of those tests can be deleted at a cost l
savings to GE.
j 1
1 2)
Our previous closed bomb testing verified our initiator / booster ability to meet the GE r
requirements.
See Gocument 17-3579 on file at GE.
i D)
Flow testing shall be performed by GE as it was on the Depressurization Valve.
2.3.3 Oualification Tests (Ref. Appendix 10 of 23ATBD)
{
r All testing for qualification.shall be GE's responsibility.
[
A cost impact to GE will be provided after the GE requirements have l
been specified.
i 2.4 Weicht i
The weight of our proposed valves is approximately 2500 lbs l
each for the 6" valve and 2300 lbs for the 4" valve.
l' l
l t
2.5 Life l
The valve will have no difficulty meeting a 60 year service
)
life; based upon the materials of construction and the use of all l
metal o-rings.
However, the initiators and boosters will. require replacement after each ten year period (this meets the GE specification requirement).
.j t
t
?
1 4.
8
O 76581
)
2.6 Maintainabilitv/ Human Encineerina Our proposed valves have been designed to provide maintenance-free service.
Valve construction and components have been kept as simple as possible, consistent with required function.
No field i
maintenance or servicing is required throughout the valve's service life except for the replacement of the initiator and booster assemblies at the required time intervals.
The valves can be refurbished after actuation within the required time established by GE provided the necessary refurbish kit is on hand and available at GE or the test facility as applicable.
2.7 Safety The valve's sealing provisions ensure that no spark, flame, gas or other effluent will be expelled during operation.
The piston, ram and sheared nipples are the only moving parts and are completely contained.
During normal firing no shrapnel or projectiles are produced.
However, the valve with the initiators and booster installed, should be treated with the normal precautions to avoid accidental ignition from such sources as stray currents, static electricity, heat or open flames.
2.8 Related Experience All the disciplines - - - such as design, material selection, stress analysis-and reliability - - - required for the proposed valves have been employed in the
- design, development, and qualification of the valves shown in Table I which are similar to the proposed valve.
We are therefore confident that we have the experience and knowledge to successfully complete the Valve Program.
2.9 Reliability We have a demonstrated reliability of.9987 at a confidence level of 90% for our normally closed valves.
2.10 Potential Problem Areas Ther are no potential problem areas provided a schedule similar to that shown in Table IV is acceptable.
9
0 76581 2.11 Comments. Clarifications. and ExceDtions a)
Pricing does not include N-Stamp requirements as required by the ASME.
An N-Stamp was not required on the prior development program for GE on the 7"
Depressurization Valve and is considered as not applicable for this development program.
b)
We take exception to the ASME code for the nipple shear sections.
By design these parts must be excluded if proper valve function is to be achieved.
This exception was acceptable to GE on the Depressurization Valve.
c) 17-4PH is reouired for some components and was used on the GE Valve.
However, this is not a 300 series of carbon steel material.
d)
The requirements for sensitization testing per E50YP20 may lead to more than one mill run of material.
Our pricing is based upon successful results the first time.
Should the raw materials not meet the applicable requirements of E50YP20, then an additional mill run or runs, of raw material, will be required; if indeed GE requires this sensitization for a development program.
The additional costs associated with this effort would be passed on to GE as applicable.
10
l 76581 l
TABLE I SQUIB VALVES Part Size Construction Customer Program Number (in) 1078 1/4 CRES Rocketdyne Gemini A 1080 3/8 CRES Rocketdyne Gemini A 1080 3/8 CRES McDonnell Gemini B l
Douglas 1120 1/4 Al Alloy &
JPL Mariner 64, 67 CRES 1120 1/4 Al Alloy &
TRW Mariner 69 CRES 1233-5 1/4 CRES Bell Minuteman III Aerospace 1249-2 1/4 CRES Ryan Firebee II 1259 1/4 CRES TRW Intelsat 1304-1 1/2 CRES Bell Mi nuteman III Aerospace
- 1312, 3/8 CRES TRW Multimission Bi-
- 1313, 3/8 Propellant
- 1315, 1/4 Propulsion 1316 1/4 1321 1/4 CRES Various Various 1321-7 1/4 CRES Philco Ford FAIR 1321-8 1/4 CRES Sandia Classified 1321-10 1/4 CRES Hamilton ITV i
Standard 1321-11 3/8 CRES Rocketdyne K-HIT 1321-12 MS33656E6 CRES Ball Unknown Aerospace 1321-14 3/16 CRES Aerojet ALAS 1327 1/2 CRES JPL Unknown 1350 1/2 CRES Martin Mariner 71 Marietta 1350-1 1/2 CRES Martin Viking 75, Marietta Voyager I, II 11
e l
76581 TABLE I SQUIB VALVES Part Sise Construction Customer Program Number (in) l 1350-7 1/2 CRES Rockwell P-80 Inter-national 1350-9 1/2 CRES McDonnell DM43 Douglas l
1350-10 1/2 CRES GD/SSD Atlas I 1350-11 1/2 CRES Rocket Atlas II Research 1350-12 1/2 CRES OSC PIK 1350-13 1/2 CRES GE/ASD Landsat 1352-4 1/2 Aluminum /
Lockheed Nimbus Spacecraft CRES 1353 1/4 Al Alloy &
JPL Mariner 71 CRES 1366 2
CRES Rockwell Skylab Internationa 1
1366-2 2
CRES MMC Shuttle External Tank 1366-3 2
CRES LMSC Commercial 1377 1/2 CRES Martin Titan III E Marietta 1380-1/4 CRES Lockheed USAF Classified 2,
-3 1420 3/4 CRES Martin Viking 75 Marietta 1420-4 3/4 CRES Martin TOS Marietta 1420-5 3/4 CRES MMC TOS-MO 1420-6 3/4 CRES MMC VRM 1426 3/8 Ti JPL TOPS
- 1430, 1/4 CRES Martin Viking 75 1430-1 Marietta 1430-3 1/4 CRES Sterer Galileo 12 j
C
^
.lj 76581
'p i
5 j
i_
^
e j.
~}!
h l1 i
s e
E og 2
' el r
sj ig
', J m-l lh e
'I
[2 f
ir m
[l h lIf L
1 u,=
4 g/g y
i g'!p.=h
. %s.
s p
- =
4 w
w
~
S
~~
j\\-
i e_.ammesi.
/7/.,)
m!pi.
I. e i
d 1
/
t i
1 I
E i1 e.
'O II a
7 p' :[
c.
7 I i3 j'
- a li g
.a s
-, l i
.1, c:
6-at i
~
C-l ni 5.
m fg-~y,-;
e
/ ;
j e
y ll dye,<
ww w
- c\\h s/
. nm
- t,,:
~
2 1
i1 V h
3
.g N'
9
.e gn L..
!A~'~N1g_s 9B p
x a
1 f~~. c
\\
J
~T k
M i
~
l
\\
@@h*
~
9-
- e e
e s
N 1
ans E
O E
un 35 1 E
t'O 0
g a
30 l
u I
a
~
76581 o
i o
4 m
I
,!f 7
I i
4 r
g '
fggl
-I l
l.
- --- g g. ~
[
sl y
u
$5 E$5
$ \\
I' s
I 5
I e
d i
i v
}1 1
i S
5 L
27 i
!ld E
C C;
s a E
i &3 S
.I f!
I; [ I.h. o!sh.. ;.
,*!! Ih.$
t 2 =
i r
i-er.
us.
p r\\
3
$$d dL' d f kit f i
E R
I e
min Op
$5 5 g$h: [pr.
)
,j[,llh i
t 9
c s
i
- I 3
m g
-reu i
_ _.:g y
{
j
- 8 F? e
- W=t-r a.-t*a=
(
i
- bb 'b L
--- 4:1-b4 tI:
~
- ]
l
'l 9
a, l
x] y y
m
?
lt N.
i bN K
)~h,i Il Ii illi Md I
w//n%,,
MW-2 o
i i
a
\\
I pir :
s w
s,~
[
Ii' S
!!;j illiil a
.4I Nd j c
e e-l e
2 l
l e
r y
c a
I e
c
.I l
4 e
i
- l'
'l l, ;I Y.
s A'
au2N u N
,['-
A' ly l
@WI d
l m
\\M L
"g@$}g
-7
%Ol f /g #~
j ji(
f/
$f m\\
////
Y/
h\\b
" ' "li 4
/
a
/
pb hW 1
I i
b i
I i
i t
il e
31 o
l o
g 4
w
i l
~
l OVERSIZE DOCUMENT PAGE PULLED I
l SEE APERTURE CARDS
}
NUMBER OF OVERSIZE PAGES FILMED ON APERTURE CARDS I
9305Aco3c/c APERTURE CARD /HARD COPY AVAILABLE FROM RECORDS AND REPORTS MANAGEMENT BRANCH i
i i
-.